Development of Process Optimization for an Intelligent Knowledge-Based System for Spur Gear Precision Forging Die Design

2004 ◽  
Author(s):  
El-Sayed Aziz ◽  
C. Chassapis
Keyword(s):  
Parametric Design ◽  
Metal Flow ◽  
Optimization Method ◽  
Spur Gear ◽  
Die Design ◽  
Design System ◽  
Process Conditions ◽  
System Utilization ◽  
Forging Process ◽  
Precision Forging

Forging sequence design is mainly carried out using empirical rules for the design of the intermediate die shapes, in addition to many trail-and-error runs resulting in prolonged development times and higher costs. An integrated optimal design of preform shapes and process conditions approach to minimize the energy required is essential. The research presented in this article aims at developing an optimization algorithm to determine the optimum intermediate die shape-designs that minimize the total energy required during the forging process sequence. It is based on the results obtained in the previous research with focus on knowledge base and database representation to design precision forging solid gears and provide detailed process specification. A three-step algorithm, which addresses gear construction design, manufacturability analysis of gear construction and die-design optimization, is used to generate the parametric gear model and automatically extract design information for manufacturing process planning based on the feature-based parametric design system. Utilization of the shape optimization method for preform stages avoids costly production problems. The optimized approach provides accurate description of all stages involved in the forging process. Forging load and energy required, along with metal flow and detailed geometry specification of die forms for every forging stage are obtained. The forging energy requirements based on this approach are as much as 25% lower than those arrived from die designs based on actual tooth profile geometry.

Parametric Design System of Precision Forging Gear Die

2013 ◽  
Vol 712-715 ◽  
pp. 1153-1157
Author(s):  
Zheng Ru Wang ◽  
Qing Ping Zhang ◽  
Cheng Wang ◽  
Gao Xiang Cai
Keyword(s):  
3D Model ◽  
Parametric Design ◽  
Three Dimensional ◽  
Die Design ◽  
Design System ◽  
Dimensional Model ◽  
Three Dimensional Model ◽  
Precision Forging ◽  
Wide Range

Powerful function in three-dimensional design, SolidWorks now has found a wide range of applications in industrial design. The parametric design system of precision forging gear die in this paper is developed with VB language based on SolidWorks environment. It is described in detail that the establishment of important components of gear die in the three-dimensional model, the relation between parameters of the interface and model, and parameters drive mechanism. Input parameters in windows of VB interface, are automatically calculated the precise parameters of the gear part and geometric dimensions of the important components of the gear die. According to the input arameters, the three-dimensional model of the gear die’s assembly drawings is generated on SolidWorks environment. The parametric design system is able to shorten the time for constructing the 3D model of the precision forging gear die and improve the quality of the die design.

Optimization in a Design System for Complex Products

1992 ◽  
Author(s):  
Johan Malmqvist
Keyword(s):  
Parametric Design ◽  
System Optimization ◽  
Optimization Method ◽  
Design System ◽  
Design Problems ◽  
Design And Optimization ◽  
Complex Products ◽  
Knowledge Based ◽  
Product Models ◽  
Use Of Knowledge

Abstract This paper describes a system for parametric design and optimization of complex products. In the system, the use of knowledge-based and mathematical programming methods is combined. The motivation is that while knowledge-based methods are well suited for modeling products, they are insufficient when dealing with design problems that can be given an optimization formulation. This weakness was approached by including the information necessary for stating an optimization problem in the product models. A system optimization method can then be applied. The system also performs sensitivity analysis and has an interactive optimization module. The use of the system is illustrated by an example; the design and optimization of a two-speed gearbox.

Study on the Large Module Spur Gear Cold Forming Process by Means of Numerical Simulation

2011 ◽  
Vol 189-193 ◽  
pp. 2642-2646 ◽  
Author(s):  
Qian Li ◽  
Yi Bian ◽  
Zhi Ping Zhong ◽  
Gui Hua Liu ◽  
Ying Chen
Keyword(s):  
Numerical Simulation ◽  
Simulation Method ◽  
Spur Gear ◽  
Cold Forging ◽  
Forming Process ◽  
Cold Forming ◽  
Forging Process ◽  
Flow Method ◽  
Precision Forging ◽  
Cold Precision Forging

The cold forging process of large module spur gear with four modules and 59mm breadth is performed by means of numerical simulation method. Two processes to forming such spur gears were compared by the simulation method, one is with the closed-die performing and extrusion in the finish-forging, the other is with divided-flow method in the finish-forging. Especially, the divided-flow method is analyzed in detail. The necessary reference and basis to realize practical cold precision forging process of spur gear with large modulus is provided eventually.

Effects of Friction on Precision Forging Process of Blade with a Damper Platform

2007 ◽  
Vol 561-565 ◽  
pp. 831-834 ◽  
Author(s):  
Yu Li Liu ◽  
He Yang ◽  
Tao Gao
Keyword(s):  
High Efficiency ◽  
Metal Flow ◽  
Vibration Characteristic ◽  
Technological Parameters ◽  
Forging Process ◽  
Precision Forging ◽  
Blade Forging ◽  
Deformation Defects ◽  
3D Software ◽  
Deform 3D

A blade with a damper platform, with excellent anti-vibration characteristic and high efficiency, has become one of the most important types of blades being developed in the aeronautical engines. During the precision forging process of this blade, the friction between dies and workpiece has important effects on metal flow, deformation defects, load and energy etc. So researching the effects of friction conditions on the forging process of blade with a damper platform has been a crucial problem urgent to be resolved. In this paper, the precision forging process of titanium alloy blade with a damper platform under different friction conditions has been simulated and analyzed based on the DEFORM-3D software platform. The obtained results reveal the influence laws of friction on temperature field and load-stroke curves, and provide a significant basis for determining technological parameters of the blade forging process.

Research on Function-Structure Mapping Method in Parametric Design Based on Axiomatic Principles

2010 ◽  
Vol 143-144 ◽  
pp. 813-817
Author(s):  
Shao Fei Jiang ◽  
Shuai Chen ◽  
Cong Da Lu
Keyword(s):  
Parametric Design ◽  
Optimization Method ◽  
Mapping Method ◽  
Design Stage ◽  
Design System ◽  
Structure Mapping ◽  
Function Structure ◽  
Mapping Procedure ◽  
Mapping Model ◽  
Mapping Mechanism

Most of the input of parametric design system is the specific structure parameter, which is in a detailed design stage. To promote it into conceptual stage, the function-structure mapping problem is proposed. To solve the problem, the function -structure mapping mechanism which is based on logical view and in the framework of axiomatic design is established, the mapping model is solved by optimization method and the mapping procedure is integrated with parametric design system. Function requirements are mapped into a parametric model directly. Finally, a forklift design process validates the method and shows its advantage.

Numerical Simulation and Die Design for Vibration Extrusion of Spur Gear

2012 ◽  
Vol 580 ◽  
pp. 37-41
Author(s):  
Qiong Lin ◽  
Bin Meng ◽  
Qing Hua Yang
Keyword(s):  
Numerical Simulation ◽  
Flow Characteristic ◽  
Metal Flow ◽  
Spur Gear ◽  
Extrusion Process ◽  
Die Design ◽  
Forming Process ◽  
Extrusion Die ◽  
Die Structure ◽  
Metal Extrusion

The numerical simulation for spur gear vibration extrusion is performed in this paper. The metal flow characteristic and load-stroke relationship during forming process is analyzed and then compared with traditional metal extrusion process. The results revealed the axial vibration of cavity die can both reduce forming load and benefit for metal flow, which could achieve better forming quality. Finally according to the processing requirements, the vibration generator and whole extrusion die structure is designed.

Investigation of Precision Forging Process of Spur Gears: Numerical Analysis and Experiments

2011 ◽  
Vol 341-342 ◽  
pp. 265-270
Author(s):  
M. Zadshakoyan ◽  
E.Abdi Sobbouhi ◽  
H. Jafarzadeh
Keyword(s):  
Numerical Analysis ◽  
Effective Strain ◽  
Spur Gear ◽  
Model Material ◽  
Optimum Number ◽  
Spur Gears ◽  
Specific Pressure ◽  
Rigid Plastic ◽  
Forging Process ◽  
Precision Forging

In this study, the precision forging process of spur gears has been investigated by means of numerical analysis. The effect of some parameters such as teeth number and module on the forming force and specific pressure were presented. The simulation works were performed rigid-plastic finite element method using DEFORM 3D software. In order to validate the estimated numerical results, they were compared with those obtained experimentally during precision forging of spur gear using lead as a model material. Results showed that the optimum number of gear teeth is between 10 to 20, that is because of being the specific pressure in its minimum value. Also the results obtained from analyzing the effective strain distribution showed that the maximum strain is located on the root area of the teeth. The work presented in this paper might be used for basic data in the design of the precision forging process.

Finite Element Analysis and Optimization of Deformation Behavior for Spur Gear Warm Forging Process

2010 ◽  
Vol 148-149 ◽  
pp. 854-858
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Ke Ke Sun ◽  
Guo Cheng Ren ◽  
Gui Qing Wang
Keyword(s):  
Finite Element ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
Helical Gears ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Warm Forging

Recent years have therefore seen growing interest in gear precision forging to net-shape form of forge bevel, spur and helical gears, as an alternative to conventional manufacturing. In this paper, gear precision forging processes are simulated by using metal forming finite element code DEFORM-3D. The investigations of gear precision forging processes are conducted with perform forging and final forging processes. The processes of completely closed-die forging, moving-die forging and central divided flow forging processes are investigated for spur gears. The effect of different processes on the distribution of effective stress in the workpieces and forging loads are given. The purpose of this study is to introduce a new method, a so-called floating-relief method which applied to the forging of spur gears. It indicated that the flowing properties of the gear billet have a higher improve than that of conventional forging process. And the forging load obtained by using this new precision forging technology is decline sharply. The floating-relief method for gear precision forging is a sound process in the practical application.

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